Slide rail assembly and landing gear assembly with embedded hardpoint connectors

ABSTRACT

Below is a clean version of the Abstract, as requested to be amended herein: A cargo vehicle is disclosed having a composite floor assembly with at least one embedded hardpoint connector. The composite floor assembly may comprise a plurality of transverse beams and at least a portion of the composite floor includes at least one embedded hardpoint connector. The embedded connector may be used to securely and removably couple other vehicle components to the composite floor assembly, such as a landing gear assembly and/or a slide rail assembly.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/764,693, filed Aug. 15, 2018, the entire disclosure of which ishereby expressly incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to floor structures and methodsof making the same. More particularly, the present disclosure relates tocomposite floor structures with embedded hardpoint connectors for use incargo vehicles and methods of making the same.

BACKGROUND OF THE DISCLOSURE

Cargo vehicles are used in the transportation industry for transportingmany different types of cargo. Cargo vehicles may be constructed usingcomposite materials, which may lead to an absence of or reduction inmetallic and wood materials and associated advantages, includingsimplified construction, thermal efficiency, reduced water intrusion andcorrosion, and improved fuel efficiency through weight reduction, forexample. However, it is desired to strengthen connections between thecomposite materials and other vehicle components. For example, it isdesired to strengthen a connection between a composite floor assemblyand a landing gear assembly, a fuel tank assembly, and/or a slide railassembly of the cargo vehicle.

SUMMARY OF THE DISCLOSURE

A cargo vehicle is disclosed having a composite floor assembly with atleast one embedded hardpoint connector. The embedded connector may beused to securely and removably couple other vehicle components to thecomposite floor assembly, such as a landing gear assembly, a fuel tankassembly, and/or a slide rail assembly.

According to an exemplary embodiment of the present disclosure, a cargobody is provided including a composite floor assembling comprising aplurality of transverse beams, a first plurality of connectors embeddedin the plurality transverse beams, and a first longitudinal beamoriented generally orthogonal to the plurality of transverse beams, eachof the first plurality of connectors positioned adjacent thelongitudinal beam.

According to another exemplary embodiment of the present disclosure, acargo body is provided including a composite floor assembly, a pluralityof connectors embedded in the composite floor assembly, a plurality ofconnectors embedded in the composite floor assembly, and a landing gearassembly coupled to the plurality of connectors using a plurality ofmechanical fasteners.

According to a further exemplary embodiment of the present disclosure, acargo body is provided including a composite flooring comprising aplurality of beams, and a slide rail assembly coupled to the pluralityof connectors using a plurality of mechanical fasteners.

According to another exemplary embodiment of the present disclosure, amethod is provided for manufacturing a composite floor assembly with atleast one embedded connector. The method includes positioning at least afirst connector and a second connector in an outer skin, the secondconnector spaced apart from the first connector, introducing anexpandable core material into the outer skin, expanding the corematerial around the at least first and second connectors in the outerskin to form a composite beam with the at least first and secondconnectors embedded therein, and arranging the composite beam with aplurality of additional composite beams to form a composite floorassembly.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiments exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the intended advantages of thisinvention will become more readily appreciated as the same becomesbetter understood by reference to the following detailed descriptionwhen taken in conjunction with the accompanying drawings.

FIG. 1 is a top perspective view of an exemplary semi-trailer of thepresent disclosure including a composite floor assembly;

FIG. 2 is a bottom plan view of the exemplary semi-trailer of FIG. 1,shown with a landing gear assembly and a slide rail assembly coupled tothe composite floor assembly;

FIG. 3 is a bottom plan view of the composite floor assembly of FIG. 1,shown without the landing gear assembly and the slide rail assembly;

FIG. 4 is a bottom perspective view of the landing gear assembly coupledto a plurality of transverse composite beams of the composite floorassembly;

FIG. 5 is a partial rear view of the landing gear assembly coupled to atransverse beam of FIG. 4, with an embedded connector shown in phantom;

FIG. 6 is a diagrammatic view of a plurality of transverse compositebeams and embedded connectors, with a plurality of longitudinal beamsshown in phantom;

FIG. 7 is a perspective view of the slide rail assembly coupled to aplurality of connectors embedded in a plurality of transverse compositebeams;

FIG. 8 is a diagrammatic view of a plurality of transverse compositebeams and embedded connectors, with a plurality of longitudinal beamsshown in phantom;

FIG. 9 is a partial rear view of the slide rail assembly coupled to atransverse composite beam of FIG. 8, with an embedded connector shown inphantom;

FIG. 10 is a flow chart of an exemplary method for manufacturing thecomposite floor assembly of the present disclosure;

FIG. 11 is an end view of one of the composite transverse beams of FIG.4, with a mold shown in phantom;

FIG. 12 is a bottom perspective view of another landing gear assemblycoupled to a plurality of transverse composite beams of the compositefloor assembly;

FIG. 13 is a partial exploded view of the landing gear assembly of FIG.12 coupled to the plurality of transverse composite beams and includinga fabric layer positioned between the landing gear assembly and theplurality of transverse composite beams; and

FIG. 14 is a partial rear view of the landing gear assembly of FIG. 12coupled to a transverse composite beam of FIG. 12, with an embeddedconnector shown in phantom.

Corresponding reference characters indicate corresponding partsthroughout the several views. Although the drawings representembodiments of various features and components according to the presentdisclosure, the drawings are not necessarily to scale and certainfeatures may be exaggerated in order to better illustrate and explainthe present disclosure. The exemplification set out herein illustratesan embodiment of the invention, and such an exemplification is not to beconstrued as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principals of theinvention, reference will now be made to the embodiments illustrated inthe drawings, which are described below. The embodiments disclosed beloware not intended to be exhaustive or limit the invention to the preciseform disclosed in the following detailed description. Rather, theembodiments are chosen and described so that others skilled in the artmay utilize their teachings. It will be understood that no limitation ofthe scope of the invention is thereby intended. The invention includesany alterations and further modifications in the illustrative devicesand described methods and further applications of the principles of theinvention which would normally occur to one skilled in the art to whichthe invention relates.

1. Semi-Trailer

Referring initially to FIG. 1, a semi-trailer 100 is shown forsupporting and transporting cargo. The illustrative trailer 100 extendsalong a longitudinal axis A from a front end 102 to a rear end 104. Theillustrative trailer 100 includes a cargo body 110 with a floor assembly112, a roof 114, a right sidewall 116R, a left sidewall 116L, a frontwall or nose 118, and a rear door assembly 120 having a rear frame 122and a door (not shown) to access the cargo body 110.

Moving from the front end 102 to the rear end 104, the trailer 100 alsoincludes a coupler assembly (not shown) configured to couple the cargobody 110 to a motorized tractor or another vehicle (not shown), alanding gear assembly 132 configured to support the cargo body 110 onthe ground, a fuel tank assembly 134, and a slide rail assembly 136 (seeFIG. 2) configured to couple the cargo body 110 to a rear wheel assembly(not shown). The front end 102 of the cargo body 110 may be supportedatop the tractor (not shown) via the coupler assembly (not shown) in atransport condition or atop the landing gear assembly 132 in astationary condition, and the rear end 104 of the cargo body 110 may besupported atop the wheel assembly (not shown) in either the transport orthe stationary condition.

In the illustrated embodiment of FIG. 1, cargo body 110 of trailer 100is an enclosed body. The cargo body 110 may be refrigerated and/orinsulated to transport temperature-sensitive cargo. While the conceptsof this disclosure are described in relation to a refrigerated trailer100, it will be understood that they are equally applicable to othervehicles generally, and more specifically to conventional trailers(e.g., dry freight trailers, flatbed trailers, commercial trailers,small personal trailers) and/or box or van semi-trailers, and the like.Accordingly, those skilled in the art will appreciate that the presentinvention may be implemented in a number of different applications andembodiments and is not specifically limited in its application to theparticular embodiments depicted herein.

Trailer 100 may have various features in common with the vehicles shownand described in International Publication No. WO 2016/137974 and U.S.Patent Application Publication No. 2017/0240217, the disclosures ofwhich are expressly incorporated herein by reference in their entirety.

2. Composite Materials

The cargo body 110 of trailer 100 may be constructed, at least in part,of composite materials. For example, the floor assembly 112, roof 114,right sidewall 116R, left sidewall 116L, and/or nose 118 of cargo body110 may be constructed of composite materials. As such, the floorassembly 112, roof 114, right sidewall 116R, left sidewall 116L, and/ornose 118 of cargo body 110 may be referred to herein as compositestructures.

Composite materials are generally formed by combining two or moredifferent constituents that remain separate and distinct in the finalcomposite material . Exemplary composite materials for use in thecomposite cargo body 110 include fiber-reinforced plastics (FRP), forexample carbon-fiber-reinforced plastics (CRP). Each composite structuremay be a single, unitary component, which may be formed from a pluralityof constituents or layers permanently coupled together. Other elementsof the cargo body 110 may be constructed of non-composite (e.g.,metallic) materials. For example, the rear door assembly 120 of thecargo body 110 may be constructed of metallic materials.

The composite construction of the cargo body 110 may present certainadvantages. First, because the composite structures may lack structuralmetallic components, the composite cargo body 110 may have a reducedheat loss coefficient (Ua) and improved thermal efficiency. Also, thecomposite cargo body 110 may operate to minimize outgassing of blowingagents, minimize air loss, and minimize water intrusion. Additionally,the composite cargo body 110 may be lighter in weight than a typicalmetallic cargo body, which may improve fuel efficiency. Further, thecomposite cargo body 110 may have fewer metallic structures than atypical cargo body, which may make the cargo body 110 less susceptibleto corrosion. Also, the composite cargo body 110 may include fewer partsthan a typical metallic cargo body, which may simplify construction,reduce inventory, and reduce variation in manufacturing. Further, thecomposite cargo body 110 may be suitable for use with sensitive cargo,including foodstuffs, because the composite materials may be inert toavoid reacting with the cargo and other materials and because thecomposite materials may be easy to clean and maintain to ensure properhygiene. As a result, the composite cargo body 110 may qualify as “foodgrade” equipment.

The composite structures of the present disclosure may contain one ormore structural supports or preforms. The preform may have a structuralcore that has been covered with an outer fabric layer or skin. The outerskin may be stitched or otherwise coupled to the underlying core and/orany surrounding layers. The core may be extruded, pultruded, orotherwise formed into a desired shape and cut to a desired length. In anexemplary embodiment, the core is a polyurethane foam material oranother foam material, and the outer skin is a non-woven spun bondpolyester material, a fiberglass fabric, or another suitable material.Advantageously, in addition to its structural effect, the foam core mayhave an insulating effect in certain applications, includingrefrigerated trucking applications. Exemplary preforms include PRISMA®preforms provided by Compsys, Inc. of Melbourne, Florida.

Both the core and the outer skin of the preform may be selected toaccommodate the needs of the particular application. For example, inareas of the final structure requiring more strength and/or insulation,a low-density foam may be replaced with a high-density foam or a hardplastic block. The individual preforms may also be sized, shaped, andarranged in a manner that accommodates the needs of the particularapplication. For example, in areas of the final structure requiring lessstrength, the preforms may be relatively large in size, with the foamcores spanning relatively large distances before reaching thesurrounding outer skins. By contrast, in areas of the final structurerequiring more strength, the preforms may be relatively small in size,with the foam cores spanning relatively small distances before reachingthe surrounding outer skins. Stated differently, the preforms may beshaped as relatively wide panels in areas of the final structurerequiring less strength and as relatively narrow support beams in areasof the final structure requiring more strength.

The composite structures of the present disclosure may also contain oneor more reinforcing materials or layers around the preforms. Eachreinforcing layer may contain reinforcing fibers and may be capable ofbeing impregnated and/or coated with a resin, as discussed further inSection 8 below. Suitable fibers include carbon fibers, glass fibers,cellulose, or polymers, for example. The fibers may be present in fabricform, which may be mat, woven, non-woven, or chopped, for example.Exemplary reinforcing layers include chopped fiber fabrics, such aschopped strand mats (CSM), and continuous fiber fabrics, such as 0°/90°fiberglass fabrics, +45°/−45° fiberglass fabrics, +60°/−60° fiberglassfabrics, 0° warp unidirectional fiberglass fabrics, and other stitchedfiber fabrics, for example. Such fabrics are commercially available fromVectorply Corporation of Phenix City, Alabama. Exemplary fabrics includethe E-LM 1810 fiberglass fabric with 0° unidirectional fibers, the E-LTM3610 fiberglass fabric with 0°/90° fibers, and the E-LTM 2408 fiberglassfabric with 0°/90° fibers, for example.

According to an exemplary embodiment of the present disclosure, aplurality of different reinforcing layers may be stacked together andused in combination. For example, a chopped fiber fabric (e.g., CSM) maybe positioned adjacent to a continuous fiber fabric. In this stackedarrangement, the chopped fibers may help support and maintain theadjacent continuous fibers in place, especially around comers or othertransitions. Also, the chopped fibers may serve as a web to resistcolumn-type loads in compression, while the adjacent continuous fibersmay resist flange-type loads in compression. Adjacent reinforcing layersmay be stitched or otherwise coupled together to simplify manufacturing,to ensure proper placement, and to prevent shifting and/or bunching.

3. Composite Floor Assembly

Floor assembly 112 is shown in more detail in FIGS. 2 and 3. Theillustrative floor assembly 112 includes a lower surface 200 that facesdownward toward the ground when in use. The illustrative floor assembly112 also includes an upper surface or platform 202 (see FIG. 5) thatfaces upward when in use to support cargo or other objects. Theillustrative floor assembly 112 has a generally rectangular outerperimeter 201 with a width W, a length L, and a height H between thelower surface 200 and the upper surface 202 (see FIG. 5), although thisshape may vary. As discussed in Section 2 above and Section 8 below,floor assembly 112 may be a composite structure that is constructed, atleast in part, of composite materials.

As shown in FIG. 3, the exemplary floor assembly 112 includes aplurality of transverse composite beams 212. Illustratively, each of theplurality of transverse composite beams 212 is oriented generallyorthogonal to longitudinal axis A. More specifically, each of theplurality of transverse composite beams 212 extend in a directionperpendicular to longitudinal axis A with longitudinal ends 213R, 213Lpositioned along outer perimeter 201 of floor assembly 112 and adjacentto sidewalls 116R, 116L, respectively. The individual transversecomposite beams 212 may be constructed in accordance with Section 2above and Section 8 below. Specifically, each transverse composite beams212 may be a preform of a structural core wrapped in an outer skin.

The plurality of transverse composite beams 212 includes a first subsetof forward beams 214, specifically forward beams 214 a-d, and a secondsubset of rearward beams 216, specifically rearward beams 216 a-f. Inthe exemplary embodiment shown, beams 214, 216 are longitudinally spacedapart from one another along longitudinal axis A. More specifically,beams 214, 216 are intermixed with and separated by the remainder of theplurality of transverse composite beams 212 such that the beams 214, 216are longitudinally spaced apart along cargo body 110.

As discussed in Section 2 above, the individual transverse compositebeams 212, 214, 216 may be sized, shaped, and arranged in a manner thataccommodates the needs of the particular application. For example, arelatively large number of small, closely-spaced beams may be used forhigh-weight/high-strength applications, whereas a relatively smallnumber of large and/or spaced-apart beams may be used forlow-weight/low-strength applications.

4. Longitudinal Beams

As shown in FIG. 2, cargo body 110 includes a first and secondlongitudinal main beam 150L, 150R extending downward from bottom surface200 of floor assembly 112 along the length L of cargo body 110 parallelto longitudinal axis A and oriented generally orthogonal to theplurality of transverse composite beams 212, 214, 216. Longitudinal mainbeams 150L, 150R are illustratively positioned laterally inward oflongitudinal ends 213R, 213L of the plurality of composite beams 212,214, 216, which correspond to sidewalls 116R, 116L of cargo body 110(see FIG. 1). In the exemplary embodiment shown, longitudinal main beams150L, 150R are positioned laterally intermediate longitudinal axis A andlongitudinal ends 213R, 213L. That said, the lateral position oflongitudinal main beams 150L, 150R relative to longitudinal axis A andlongitudinal ends 213R, 213L of the lateral sides of cargo body 112 maybe adjusted depending on the specific application and components ofcargo body 110. Furthermore, the individual longitudinal main beams150L, 150R may be constructed in accordance with Section 2 above andSection 8 below. Specifically, each longitudinal main beam 150L, 150Rmay be a preform of a structural core wrapped in an outer skin.

An advantage, among others, of longitudinal main beams 150L, 150R isthat longitudinal main beams 150L, 150R provide stiffness along thelength L of floor assembly 112. Another advantage, among others, oflongitudinal main beams 150L, 150R is that longitudinal main beams 150L,150R provide a coupling surface for components of cargo body 110. Forexample, slide rail assembly 136 is coupled to a rear portion oflongitudinal main beams 150L, 150R near rear end 104. Illustratively,slide rail assembly is adhesively coupled to longitudinal main beams150L, 150R using a structural adhesive. In another embodiment, sliderail assembly 136 is mechanically coupled to longitudinal main beams150L, 150R using at least one fastener such as, for example, a bolt orscrew. Additional details regarding slide rail assembly 136 coupling tolongitudinal main beams 150L, 150R may be found in Section 7 below.

In the exemplary embodiment shown, cargo body 110 includes additionallongitudinal beams 152L, 152R, 153. Longitudinal beams 152L, 152R, 153extend along a shorter length of floor assembly 112 relative tolongitudinal main beams 150L, 150R. More specifically, longitudinalbeams 152L, 152R, 153 are positioned near front end 102 of cargo body110 without extending entirely to rear end 104 of cargo body 110. In theexemplary embodiment shown, longitudinal beams 152L, 152R, 153 provide acoupling surface for components of cargo body 110 such as, for example,landing gear assembly 132 and fuel tank assembly 134 (see FIG. 1).Additional details regarding landing gear assembly 132 coupling tolongitudinal beams 152L, 152R may be found in Section 6 below. Anotheradvantage, among others, of longitudinal beams 152L, 152R, 153 is thatlongitudinal beams 152L, 152R, 153 provide additional stiffness to floorassembly 112 near front end 102 (i.e., the area of landing gear assembly132 and fuel tank assembly 134).

Similar to the transverse composite beams 212, the individuallongitudinal beams 150L, 150R, 152L, 152R, 153 may be sized, shaped, andarranged in a manner that accommodates the needs of the particularapplication. For example, longitudinal main beams 150L, 150R may extendonly along a portion of the length L of cargo body 110. In anotherembodiment, longitudinal beams 152L, 152R, 153 are sized and arranged toaccommodate an additional fuel tank assembly or other accessorypositioned, for example, laterally opposite fuel tank assembly 134.

5. Embedded Hardpoint Connectors

Floor assembly 112 may include one or more embedded hardpoint connectors300, as shown in FIG. 3. Connectors 300 may serve as fasteners oranchors for mechanically coupling other components of trailer 100 tofloor assembly 112, such as rear door assembly 120 (FIG. 1), a couplerassembly (not shown), landing gear assembly 132 (FIG. 1 and 2) or 332(FIGS. 12-14), fuel tank assembly 134 (FIG. 1), slide rail assembly 136(FIGS. 2 and 7), and/or a suspension assembly (not shown), for example.

Each connector 300 may be configured to receive one or more mechanicalfasteners 301 (FIG. 5) from the adjacent component. Suitable mechanicalfasteners 301 include bolts, screws, rivets, and nails, for example. Incertain embodiments, connectors 300 may include pre-tapped holes (notshown) capable of receiving mechanical fasteners 301. Depending on theneeds of the particular application, mechanical fasteners 301 may beused alone or in combination with structural adhesives. Mechanicalfasteners 301 may be desired when the adjacent component will besusceptible to peeling, whereas structural adhesive may be desired whenthe adjacent component will be susceptible to shear loads. When usedalone, the mechanical fasteners 301 may facilitate efficient andinexpensive assembly and repairs of trailer 100. When used incombination with structural adhesive, the mechanical fasteners 301 mayalso serve as clamps to stabilize trailer I00 during curing of thestructural adhesive.

In the exemplary embodiment of FIG. 3, connectors 300 are illustrativelyembedded in a select group of beams of the plurality of transversecomposite beams 212. More specifically, connectors 300 are embedded inbeams 214, 216, which comprise a first and second subset of theplurality of beams 212. The remaining beams 212 may lack embeddedconnectors 300. As referenced above, one or more beams 212 lackingembedded connectors 300 may be arranged between the beams 214, 216having embedded connectors 300 such that the connectors 300 arelongitudinally spaced apart along cargo body 110.

Illustratively, connectors 300 comprise a generally planar body or plateand are embedded in lower surface 200 of composite floor 112, morespecifically within beams 214, 216 themselves. In an alternativeembodiment, connectors 300 are embedded in another surface or span twoor more surfaces of beams 214,216. Accordingly, connectors 300 may alsobe C-shaped, T-shaped, pi-shaped, bent, tubular, or other suitableshapes. The connectors 300 may be embedded in beams 214, 216 inaccordance with Section 8 below.

In the exemplary embodiment shown, each beam 214, 216 includes aplurality of embedded connectors 300, illustratively between two andfour embedded connectors 300. Generally, connectors 300 are spaced apartfrom one another along the longitudinal length of each beam 214, 216.For example, connectors 300 may be positioned intermediate longitudinalaxis A and a respective longitudinal end 213L, 213R of beams 214, 216.More specifically, connectors 300 are positioned laterally inward oflongitudinal ends 213L, 213R of beams 214, 216 (corresponding to thelateral sidewalls 116L, 116R of cargo body 110 (see FIG. 1)). That said,the position and number of connectors 300 along the length of each beam214, 216 may be adjusted for the required application. Moreover, thesubsets of beams 214, 216 with embedded connectors 300 may be more orfewer than the number of selected beams 214, 216 shown in FIG. 3.

Connectors 300 may be constructed of metallic materials (e.g., steel,aluminum, titanium), polymeric materials, wood, or composite materials.In certain embodiments, connectors 300 are constructed of materialswhich are dissimilar from the composite material used to construct thecorresponding beams. Connectors 300 may be fabricated by extrusion,pultrusion, sheet forming, roll forming, and/or casting, for example.Connectors 300 may also be single-piece or multi-piece constructs. Formulti-piece constructs, the pieces may be welded, mechanically fastened,adhered, snap-fit, or otherwise coupled together.

6. Landing Gearing Assembly

Turning now to FIGS. 4-6, an exemplary landing gear assembly 132 isprovided for use with front beams 214 of floor assembly 112. Asdiscussed above, landing gear assembly 132 may be used to support thecargo body 110 on the ground.

The illustrative landing gear assembly 132 includes mounting brackets133L, 133R, each having at least one horizontal portion 310 and aU-shaped portion 312. The horizontal portion 310 of each mountingbracket 133L, 133R is mechanically coupled to connectors 300 embedded inbeams 214 a, 214 b, 214 c using a plurality of mechanical fasteners 301.In addition, the U-shaped portion 312 of each mounting bracket 133L,133R wraps around at least a portion of and is adhesively coupled to thecorresponding longitudinal beam 152L, 152R using a structural adhesive,for example, and/or mechanical fasteners.

As shown in FIG. 6, longitudinal beams 150, 152, 153 are positionedlaterally inward of longitudinal ends 213L, 213R of beams 214. Moreover,longitudinal main beams 150L, 150R are positioned laterally inwards oflongitudinal beams 152L, 152R. In the exemplary embodiment shown,longitudinal beam 153 is positioned laterally inward of longitudinalmain beams 150L, 150R. Furthermore, connectors 300 are positionedadjacent their respective longitudinal beam. For example, connectors300L are positioned adjacent and laterally outward of longitudinal beam152L and connectors 300R are positioned adjacent and laterally outwardof longitudinal beam 152R. Similarly, connector 300 a is positionedadjacent and laterally outward of longitudinal main beam 150L andconnector 300 b is positioned adjacent and laterally outward oflongitudinal main beam 150R. Connector 300 c is positioned adjacent andlaterally inward of longitudinal beam 153. As a result, connectors 300are positioned laterally intermediate their respective one oflongitudinal beams 150, 152, 153 and outer perimeter 201 of floorassembly 112.

Referring back to FIG. 5, longitudinal beam 152R includes a corematerial 160 extending along the longitudinal length of longitudinalbeam 152R. Core material 160 may comprise a foam, for example.Connectors 300R are positioned laterally adjacent core material 160.Depending on the size and shape of connectors 300 and/or longitudinalbeams 150, 152, 153, core material 160 may be entirely offset from ormay overlap at least a portion of connectors 300 when connectors 300 areembedded in beams 214. In the exemplary embodiment shown, longitudinalbeam 152R further includes an outer skin 162 surrounding at least aportion of core material 160 and coupled to lower surface 200 of floorassembly 112. Outer skin 162 may comprise a fiberglass fabric, forexample. Connectors 300R may be aligned with outer skin 162 oflongitudinal beam 152R when connectors 300R are embedded in beams 214.Like the landing gear assembly 132, the fuel tank assembly 134 (FIG. 1)may be coupled to front transverse beams 214 of floor assembly 112. Forexample, the fuel tank assembly 134 may be adhesively coupled tolongitudinal beams 152L and 153 (at a location rearward of the landinggear assembly 132) and mechanically coupled to the adjacent connectors300L, 300 c, respectively.

7. Slide Rail Assembly

Referring next to FIGS. 7-9, an exemplary slide rail assembly 136 isprovided for use with beams 216 of floor assembly 112. As discussedabove, slide rail assembly may be used to couple cargo body 110 to arear wheel assembly (not shown).

The illustrative slide rail assembly 136 includes mounting brackets137L, 137R, each having at least one horizontal portion 320 and aU-shaped portion 322. The horizontal portion 320 of each mountingbracket 137L, 137R is mechanically coupled to connectors 300 embedded inbeams 216 a-fusing a plurality of mechanical fasteners 301. In addition,the U-shaped portion 322 of each mounting bracket 137L, 137R wrapsaround at least a portion of and is adhesively coupled to thecorresponding longitudinal main beam 150L, 150R using a structuraladhesive, for example, and/or mechanical fasteners.

As shown in FIG. 8, longitudinal main beams 150L, 150R are positionedlaterally inward of longitudinal ends 213L, 213R of beams 216.Connectors 300 are positioned adjacent their respective longitudinalbeam. For example, connectors 300L are positioned adjacent and laterallyoutward of longitudinal main beam 150L and connectors 300R arepositioned adjacent and laterally outward of longitudinal main beam150R. As a result, connectors 300 are positioned laterally intermediatetheir respective one of longitudinal beams 150L, 150R and outerperimeter 201 of floor assembly 112.

Turning now to FIG. 9, longitudinal beam 150R includes core material 166extending along the longitudinal length of longitudinal beam 150R. Corematerial 166 may comprise a foam, for example. Connectors 300R arepositioned laterally adjacent core material 166. Depending on the sizeand shape of connectors 300 and/or longitudinal beams 150L, 150R, corematerial 166 may be entirely offset from or may overlap at least aportion of connectors 300 when connectors 300 are embedded in beams 216.In the exemplary embodiment shown, longitudinal beam 150R furtherincludes an outer skin 164 surrounding at least a portion of corematerial 166 and coupled to lower surface 200 of floor assembly 112.Outer skin 164 may comprise a fiberglass fabric, for example. Connectors300R may be aligned with outer skin 164 of longitudinal beam 152 whenconnectors are 300R are embedded in beams 214.

8. Composite Molding Process

Turning now to FIGS. 10 and 11, the composite structures of the presentdisclosure may be formed by a molding process 350, as discussed furtherbelow.

The illustrative method 350 involves fabricating each transverse beam212, 214 a-d, 216 a-f as a preform and then incorporating the preformsinto the final floor assembly 112. At step 352, a mold 400 having adesired shape is provided. At step 354, interior surfaces of mold 400are covered with outer skins 218, 220. Outer skins 218, 220 may comprisea fiberglass fabric, for example. Moreover, outer skins 218, 220 may beof the same or different fabric weight. For example, outer skin 220 maybe of a heavier fabric weight than outer skin 218. At step 356, anydesired connectors 300 are placed inside the outer skins 216, 218 inmold 400. With respect to the illustrative beam 214 a of FIGS. 6 and 11,for example, connectors 300L, 300R (not shown in FIG. 11) are spacedapart from one another along the intended longitudinal length of beam214 a within mold 400. Step 356 may be omitted when forming a transversebeam 212 that lacks connectors 300. At step 358, the expandable corematerial 222 is injected or otherwise introduced into the outer skins216, 218 to contact connectors 300, if present. At step 360, the corematerial 222 expands and cures within the outer skins 216, 218 andaround connectors 300, if present, which holds connectors 300 in place.At step 362, a preform resembling the desired beam 212, 214 a-d, 216 a-fis removed from mold 400. At step 364, the preform is incorporated intothe final floor assembly 112, which may involve arranging the preformwith other preforms (e.g., beam 214 a of FIG. 11 may be arranged withother beams 212, 214 b-d, 216 a-f) and reinforcing layers, wetting thematerials with at least one resin and a catalyst to impregnate and/orcoat the materials, and curing the materials to form the final floorassembly 112.

The resin used to construct the composite structure may be a typicalthermoset resin, a co-cure resin containing a plurality of individualco-curing resins which may be selectively distributed throughout thecomposite structure during the molding process, or a combinationthereof. Such co-cure resins may comprise one or more elastomercomponents, such as urethane, co-cured with one or more resincomponents, such as a vinyl ester, epoxy, or unsaturated polyestercomponents. Exemplary co-cure resins are disclosed in U.S. Patent No.9,371,468 and U.S. Publication No. 2016/0263873, the disclosures ofwhich are hereby incorporated by reference in their entirety. As usedherein, “co-cured” refers to the reactions involved in curing theelastomer components take place essentially concurrently with thereactions involved in curing the one or more resin components. Incertain embodiments, areas of the composite structure that will besusceptible to high stress may receive a resin with a relatively higherpolyurethane content for strength, whereas other areas of the compositestructure that provide bulk and section modulus may receive a lower costrigid, polyester-based resin, such as an isophthalic polyester resin.

Additional information regarding the construction of compositestructures is disclosed in the following patents and published patentapplications, each of which is incorporated by reference in its entiretyherein: U.S. Patent Nos. 5,429,066, 5,664,518, 5,800,749, 5,830,308,5,897,818, 5,908,591, 6,004,492, 6,013,213, 6,206,669, 6,496,190,6,497,190, 6,543,469, 6,723,273, 6,755,998, 6,869,561, 6,911,252,8,474,871, and 10,239,265.

9. Another Landing Gear Assembly

Referring now to FIGS. 12-14, another landing gear assembly 332 isshown. Like landing gear assembly 132 (see FIGS. 4-6), landing gearassembly 332 may be used to support cargo body 110 on the ground.

Landing gear assembly 332 is illustratively coupled to a floor assembly112′. Like floor assembly 112, floor assembly 112′ includes a lowersurface 200′ that faces downward toward the ground when in use and anupper surface or platform 202′ that faces upward when in use to supportcargo or other objects. Floor assembly 112′ has a generally rectangularouter perimeter 201′, although this shape may vary. In the exemplaryembodiment shown, floor assembly 112′ extends axially along alongitudinal axis A′ from front end 102 of trailer 100 to rear end 104of trailer 100 (see FIG. 1). As discussed in Sections 2 and 8 above,floor assembly 112′ may be a composite structure that is constructed, atleast in part, of composite materials.

As shown in FIG. 12, floor assembly 112′ includes a plurality oftransverse composite beams 212′. Illustratively, each of the pluralityof transverse composite beams 212′ is oriented generally orthogonal tolongitudinal axis A′. More specifically, each of the plurality oftransverse composite beams 212′ extend in a direction perpendicular tolongitudinal axis A′ with longitudinal ends 213′L, 213′R of transversecomposite beams 212′ positioned along outer perimeter 201′ of floorassembly 112′ and adjacent to sidewalls 116L, 116R, respectively, ofcargo body 110 (FIG. 1). The individual transverse composite beams 212′may be constructed in accordance with Sections 2 and 8 above.Specifically, each transverse composite beam 212′ may be a preform of astructural core wrapped in an outer skin.

Illustratively, the plurality of transverse composite beams 212′includes a first subset of beams 214′, specifically beams 214′a-e, whichare intermixed with the remainder of the plurality of transversecomposite beams 212′. In the exemplary embodiment shown, forward beams214′a, 214′b are positioned adjacent one another, intermediate beam214′c is spaced apart from forward beams 214′a, 214′b along longitudinalaxis A′, and rearward beams 214′d, 214′e are positioned adjacent to oneanother and spaced apart from intermediate beam 214′c along longitudinalaxis A′. As discussed in Section 2 above, the individual transversecomposite beams 212′, 214′ may be sized, shaped, and arranged in amanner that accommodates the needs of the particular application. Forexample, a relatively large number of small, closely-spaced beams may beused for high-weight/high-strength applications, whereas a relativelysmall number of large and/or spaced-apart beams may be used forlow-weight/low-strength applications.

Referring now to FIG. 13, floor assembly 112′ includes a plurality ofembedded hardpoint connectors 300, specifically connectors 300L, 300Rthat serve as fasteners or anchors for mechanically coupling landinggear assembly 332 to floor assembly 112′. As discussed in Section 3above, floor assembly 112′ may also include a second subset of rearwardbeams 216′ having at least one connector 300 to which slide railassembly 136 may be coupled.

Floor assembly 112′ also includes longitudinal main beams 150L, 150Rextending downward from bottom surface 200′. Longitudinal main beams150L, 150R are oriented generally orthogonal to the plurality oftransverse composite beams 212′, 214′and generally parallel tolongitudinal axis A′. Longitudinal main beams 150L, 150R areillustratively positioned laterally inward of longitudinal ends 213′L,213′R of the plurality of composite beams 212′, 214′, which correspondto sidewalls 116L, 116R of cargo body 110 (see FIG. 1). In the exemplaryembodiment shown, longitudinal main beams 150L, 150R are positionedlaterally intermediate longitudinal axis A′ and longitudinal ends 213′L,213′R. Connectors 300L, 300R are positioned laterally intermediate arespective one of longitudinal main beams 150L, 150R and longitudinalends 213′L, 213′R of beams 214′a-e. The individual longitudinal mainbeams 150L, 150R may be constructed in accordance with Sections 2 and 8above. Specifically, each longitudinal main beam 150L, 150R may be apreform of a structural core wrapped in an outer skin. In otherembodiments, because longitudinal main beams 150L, 150R are not used tosupport or anchor landing gear assembly 332, longitudinal main beams150L, 150R may be shortened or eliminated at least in the area oflanding gear assembly 332.

Landing gear assembly 332 includes T-shaped mounting brackets 334L,334R, each having at least one vertical portion 336 and at least onehorizontal portion 338. Vertical portion 336 may be integrally formedwith horizontal portion 338 to form a single piece construction, orvertical portion 336 and horizontal portion 338 may be separate piecesthat are coupled together (e.g., welded). In the exemplary embodimentshown, mounting brackets 334L, 334R are formed from extruded aluminum.The horizontal portion 338 of each of mounting brackets 334L, 334R mayinclude one or more holes located on one or both sides of thecorresponding vertical portion 336 to receive mechanical fasteners 339on one or both sides of the corresponding vertical portion 336.Connectors 300L, 300R are aligned with corresponding mounting brackets334L, 334R as shown in FIG. 14 such that mounting brackets 334L, 334Rare mechanically coupled to connectors 300L, 300R using mechanicalfasteners 339. The horizontal portion 338 may also be adhesively coupledto bottom surface 200′ of floor assembly 112′ using, for example, astructural adhesive. An advantage, among others, of mounting brackets334L, 334R is that landing gear assembly 334 may be coupled to bottomsurface 200′ of floor assembly 112′ without the need for longitudinalbeams 152L, 152R (see FIG. 5).

To accommodate coupling landing gear assembly 332 to bottom surface 200′of floor assembly 112′, one or more additional reinforcing layers may beadded to the vertical wall portions of beams 214′a-e. The addition ofone or more reinforcing layers increases the strength and/or stiffnessof beams 214′a-e. This reinforcing layer may contain reinforcing fibersand may be capable of being impregnated and/or coated with a resin, asdescribed in Sections 2 and 8 above. In the exemplary embodiment shown,the reinforcing fibers are present as chopped fiber fabrics. Inaddition, at least one reinforcing layer 340, illustratively reinforcinglayers 340L, 340R, is positioned between connectors 300L, 300R embeddedin beams 214′a-e and a respective one of mounting brackets 334L, 334R.In the exemplary embodiment shown, each reinforcing layer 340L, 340Rcomprises a glass fiber mat, as discussed in Section 2 above. Anadvantage, among others, of reinforcing layer 340 is increasing thepull-out or pull-through strength of embedded connectors 300L, 300R inbeams 214′a-e. In another embodiment, a single reinforcing layer 340 maybe used that spans both mounting brackets 334L, 334R. The size and typeof reinforcing layer 340 may be dependent upon the load and applicationof cargo body 110.

While this invention has been described as having an exemplary design,the present invention may be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractices in the art to which this invention pertains.

1.-23. (canceled)
 24. A cargo body, comprising: a composite floorassembly comprising a plurality of transverse beams; and a plurality ofconnectors embedded in at least a portion of the composite floor. 25.The cargo body of claim 24, wherein the plurality of connectors isembedded within the composite floor at a position laterally outward of alongitudinal axis of the composite floor.
 26. The cargo body of claim25, wherein the composite floor includes a first lateral side and asecond lateral side, and the longitudinal axis of the composite floor isequidistant from the first and second lateral sides, and at least afirst connector of the plurality of connectors is positioned laterallybetween the first lateral side and the longitudinal axis, and at least asecond connector of the plurality of connectors is positioned laterallybetween the second lateral side and the longitudinal axis.
 27. The cargobody of claim 26, wherein the first and second connectors are laterallyaligned.
 28. The cargo body of claim 26, wherein the first and secondconnectors are longitudinally offset from each other.
 29. The cargo bodyof claim 24, wherein the composite floor includes an upper surface and alower surface generally opposite the upper surface, and the plurality ofconnectors is embedded within the composite floor at a position adjacentthe lower surface.
 30. The cargo body of claim 29, wherein each of theplurality of connectors includes a first portion positioned on a firstside of the lower surface and a second portion positioned on a secondside of the lower surface.
 31. The cargo body of claim 30, wherein thesecond portion includes at least one aperture configured to receive aremovable fastener.
 32. The cargo body of claim 31, wherein the firstportion is embedded within the composite floor.
 33. The cargo body ofclaim 24, wherein the plurality of connectors is embedded in theplurality of transverse beams.
 34. The cargo body of claim 33, whereineach of the plurality of transverse beams is formed from a core materialand an outer skin, and wherein each of the plurality of connectors isembedded in the core material and surrounded by the outer skin of thecorresponding beam.
 35. A cargo body, comprising: a composite floorassembly; a plurality of connectors embedded in a first portion of thecomposite floor assembly; and a landing gear assembly coupled to theplurality of connectors using a plurality of mechanical fasteners andadhered to a second portion of the composite floor assembly.
 36. Thecargo body of claim 35, wherein: the plurality of connectors includes aleft connector embedded in a left side of the composite floor assemblyand a right connector embedded in a right side of the composite floorassembly; the landing gear assembly includes a left mounting bracketaligned with and fastened to the left connector and a right mountingbracket aligned with and fastened to the right connector.
 37. The cargobody of claim 36, wherein: the left mounting bracket is T-shaped with avertical portion and a horizontal portion, the horizontal portiondefining apertures aligned with the left connector on either side of thevertical portion; and the right mounting bracket is T-shaped with avertical portion and a horizontal portion, the horizontal portiondefining apertures aligned with the right connector on either side ofthe vertical portion.
 38. A cargo body, comprising: a composite floorassembly including a plurality of beams; a plurality of connectorsembedded in the composite floor; and a slide rail assembly coupled tothe plurality of connectors using a plurality of mechanical fasteners.39. The cargo body of claim 38, wherein the plurality of beams areoriented generally orthogonal to a longitudinal axis of the compositefloor assembly.
 40. The cargo body of claim 38, wherein the plurality ofbeams includes a first beam and a second beam spaced apart from thefirst beam by a longitudinal distance greater than zero, and a firstconnector of the plurality of connectors is embedded in the compositefloor at a location of the first beam and spaced apart from the secondbeam, and a second connector of the plurality of connectors is embeddedin the composite floor at a location of the second beam and spaced apartfrom the first beam.
 41. A method of manufacturing a composite floorassembly with at least one embedded connector, the method comprising:positioning at least a first connector and a second connector in anouter skin, the second connector spaced apart from the first connector;introducing an expandable core material into the outer skin; andexpanding the core material around the at least first and secondconnectors in the outer skin to form at least a portion of the compositefloor with the at least the first and second connectors embeddedtherein.
 42. The method of claim 41, wherein the expandable corematerial is a foam.
 43. The method of claim 41, further comprisingpositioning the first connector on a first side of a longitudinal axisof the composite floor and positioning the second connector on a secondside of the longitudinal axis.